Process and apparatus for molding sheet material



Aug 28, 1951 w. B. CLIFFORD ET AL 2,565,949

PRocEss AND APPARATUS FOR MOLDTNG SHEET MATERIAL Filed April 12. 194'.7 2 sheetssheet 1 T5-H /4 ff ff MNHN 23 Z4@ l l /9 Aug 28, 1951 w. B. CLIFFORD ETAL 2,565,949

PEocEss AND APPARATUS FOR MoLnING SHEET MATERIAL Filed April 12. 194'.7

2` Sheets-Sheet 2 t INVENTOR:

Il l VIII/1 Patented Aug. 28, 1951 UNITED STATES PATENT OFFICE PROCESS AND APPARATUS FOR MOLDING x SHEET MATERIAL walter B. cunard ma nanna a. warum,

Boston, Masa.

Application April l2, 1947, Serial No. 741,104

without the formation of pleats. by first engaging I the stock between flexible diaphragms which hold it securely in flat condition, and then conforming the blank by cooperating dies acting through said diaphragms. We propose to employ diaphragms of natural or synthetic rubber held in strong frictional engagement with the blank and powerfully controlling lateral ow or migration of the stock in the subsequent molding operation. The diaphragms also hold the material of the blank against such deformation as would result in the pleats that would occur if the sheet 1o` claims. (ci. 11a-44) one of the forming 'dies is enclosed. Hydraulic or gaseous fluid pressure connections are provided for imparting an equal pressure and stretch to the diaphragms beforevbringing them into engagement with the blank for equalizing pressure upon the diaphragms and for releasing fluid pressure as required.

These and other features of the vinvention will be best understood and appreciated from the following description of preferred forms of apparatus whereby the process may be carried out, the apparatus being illustrated in the accompanying drawings, in which:

Fig. l is a. view partly in elevation and partly in longitudinal section, Y

Fig. 2 is a view in front elevation, partly in section, showing the diaphragms in contact with material were engaged directly by the forming acterized by the employment of diaphragms which are stretched or expanded before they are brought into engagement \with the stock to be molded and then allowed to contract with the stock held between them in proportion to the shape and approaching movement of the dies. The stock being molded is,` therefore, drawn inwardly by the contracting diaphragms and instead of being reduced in thickness by the drawing action of the dies, it may, in some cases, actu# ally thicken in the molding operation. The diaphragms are held or clamped about their peripheries and accordingly the stretch imparted to them takes place between their clamped peripheries. This action may be visualized by assuming that the diaphragms are marked with a series of concentric circles spaced 1/" apart. If the diaphragms are now stretched until the circles are spaced 5/8" apart and the stock engaged firmly between the expanded diaphragms, the area of the blank will be reduced by an extent equal to the contraction of the diaphragms back to the l/V spacing of the circles, when the diaphragms contract with the stock, assuming no slip occurs between the stock and the diaphragms.

The process of our invention may be carried out with diaphragms having an initial convex contour and which thus may be brought into preliminary engagement with a selected portion of the blank and then caused to engage it over a progressively increasing area as they are moved together under fluid pressure. Preferably and as herein shown, each diaphragm is used to enclose a portion of a uid pressure chamber in which the blank to be molded,

Fig. 3 is a fragmentary sectional view illustrating the molding operation,

Fig. 4 is a plan view of the lower diaphragm,

Fig. 5 is a sectional view of a molded article,

Figs. 6 and 7 are views of apparatus of modified form corresponding to Figs. 1 and 2, and

Fig. 8 is a fragmentary view illustrating the molding operation as carried out by the said modified apparatus. Y

The process of our invention is not limited to or dependent upon any specific apparatus, although it may be conveniently carried out by that herein shown. 'I'he apparatus of Figs. i to 4 includes a frame IIJ formed integral with a recessed table Il having a circumferential flange I2. The female die I3 is stationary and is supported in a socket provided in the table Il The die I3 is enclosed within a hemispherical diaphragm Il which, in practice, may be formed of Hycar, neoprene or nylon or rubber about 1/4" or somewhat thicker. The rim of the diaphragm is herein shown as securely held in place uponV the metal flange I2 of the table by a clamping f ring I5 which is secured to the table.V

'I'he frame I0 carries an upstanding arm I6 which is arranged to support a vertical cylinder Il. Within the cylinder operates a plunger providing a piston I8 on a vertical shaft I9. The shaft has at its lower end a threaded Ibore into which is screwed the stem of the male die 20. The lower end of the cylinder I'I is closed by a cap 2|, and uid pressure connections 22 and 23 for oil or gas provide means for reciprocating the piston within the cylinder I'I. The shaft I9 carries at its lower. end a recessed cap 24 having a. circumferential ange to which the upper convex diaphragm 25 is secured by a clamping ring 26.

Fluid pressure is supplied to the pressure chambers formed by the ydiaphragms I4 and 25 3 by a supply pipe Il provided with a three-way valve It and having a ilexible connection Il to the upper diaphragm. The table ot the lower diaphragm is connected through a nipple ll to the supply pipe 21 and provided with a valve 3| arranged to act 'as a safety valve for the entire system.

The lower die Il and its stem are provided with a vertical bore 32 leading to an inlet connection $5 in the bottom of the table il. The connection 3l is herein shown as provided with a shut-oil' valve. 'I'he purpose oi the bore and connection is to provide means for admitting uidtotheinneriaceofthedietobreakthe r.

vacuum which is created there in the molding operation and thus to release the diaphragm i4 which would otherwise be held down in engagement with the die for a deiinite period after the molding operation.

In practice thetwo diaphragms i4 and 25 are iirst expanded by equal pressure of fluid admitted by opening the valve 28. Under this expanding pressure they both assume hemispherieal or balloon form as shown in Fig. 1, being separated by a space permitting the convenient presentation between them of the blank 33 to be molded. Successive blanks may be presented by a feeding device 34. represented conventionally in Fig. l,y and which is effective to locate the blank symmetrically and concentrically inline with the axis of thediaphragms and the forming dies. The blank I3 is now engaged between the stretched diaphragms by downward movement of the piston Il and the cap 24, this downward movement being continued until the diaphragms ilrst contact with the center oi the blank 33. then roll into engagement with it over a progressively increasing area, and finally becoming ilattened, holding the blank in ilat condition as shown in Fig. 2. It will be borne in mind that at this stage oi theprocess the two diaphragms are maintained in substantially expanded condition.

As theblank is engaged between the expanded diaphragms, the feeder 34 releases it and moves outwardly to an inoperative position. The forming die 24 is now advanced with respect to the lower forming die I3 to final molding position as indicated in Fig. 3. In this step of the process the expanding pressure upon the two diaphragms is reduced and the diaphragme are allowed to contract to an amount compensating for the distortion imparted to them by the forming dies Il and 20. During the molding operation, therefore, the blank 33 is firmly engaged by the non-slipping surfaces of the diaphragms which are meanwhile contracting and thus tending powerfully to contract the material of the blank heid between them; that is, the contracting action of the diaphragms not only prevents reduction in thickness of the blank by the drawing action o! the dies. but tends to increase the thickness of the blank by drawing it uniformly and concentrically inwardly. At the same time the diaphragms are effective to prevent the formation of wrinkles or pleats in the molded material with the result that the ilnished article produced by the'molding operation is smooth in all parts.

lIn the forming operation the lower diaphragm is forced into intimate engagement with the inner face of the lower concave die i3 and a thus freed for removal from the machine. Aitor the molded blank has been removedf-Joil is ad-v mitted through the connection I6, thewacuum beneath the diaphragm is broken and it is re leased in preparation for the next cycle o! operations. The molded blank 33 as shown in Fig. 5 will be iound to have suil'ered no reduction in cross-section at any point due to the drawing action ofthe dies, and to present a continuous smooth surface without creases or pleats.

'Ihe process of our invention may be carried out in a somewhat modiiied manner by apparatus illustrated in Figs. 6 to 8, and will now be described. This includes a frame 40 having an upstanding arm 4| in which is supported a vertical cylinder 42 provided with pressure connections 43 and 44. Within the cylinder 42 is a` piston, not shown, operating the rod or shaft 45 to the lower end oi' which is secured a female mold 48. This -mold is arranged to be moved vertically in bothdirections by fluid pressure supplied to the cylinder and exhaustedtherefrom by the connections shown.

A cap 41 oi circular outline is fastened to the shaft 45 and presents a flat lower face. To this face is secured a circular elastic diaphragm 48 by means oi a binding ring 49. Fluid under pressure may be admitted to the chamber formed within the diaphragm 48,/and lthe diaphragm may thus be blown up and expanded into semispherical shape as shown in Fig. 6.

The frame 4U also carries a stationary table 5l to which is secured a cylindrical casing 5i having a flat perforated partition 52. At its upper end the casing 5i has an outwardly directed angular iiange 53 and to this is secured an elastic diaphragm 54 by means of a clamping ring 55.

A flexible iluid pressure pipe 56 is connected through a passage in the movable cap 4l to the chamber above the diaphragm 48 and through a valve nipple 51 to the chamber beneath the diaphragm 54 formed by the table 5d and the partition 52. A three-way valve 58 controls the admission and exhaust of a fluid pressure medium to the two diaphragm chambers.

'I'he table 50 is perforated to receive the threaded stem 59 oi a head El which underlies the table 54. The head 6D is held in place by a lock nut 4l and its stem provides a passage which is connected to a vacuum pipe 62. In the drawings the. blank G4 which is to be molded is shown as resting upon the diaphragm 54.

In carrying out the process oi our invention with the assistance of the apparatus above described, the diaphragm 48 is expanded by being blown into the semi-spherical shape shown in Fig. 6,;and the diaphragm 54 is expanded by being drawn by suction created through the connection 52 into conformity with the partition 52 and the inner walls ofthe casing 5i. 'I'he diaphragm 54 is thus sucked into a position in which it presents a nat face in line with and beneath the diaphragm 48 and in which it is substantially expanded from its normal condition. 'I'he fibrous blank 64 to be molded is now placed upon the at surface o! the expanded diaphragm 54 and the piston rod 45. together with the mold 46 and the diaphragm 48, are

vacuum is thus formed which holds the diaphragm in that position. While thus held the upper diaphragm is lifted and the molded blank moved downwardly into the position shown in Fig. 7. In this step of the process the diaphragm 4l rst engages the central area oi the blank I4 and then rolls outwardly into complete engagement with it, ilnally assuming the iiattened shape shown in Fig. 7. The die 4t has meanwhile been brought into engagement with the inner surface of the diaphragm 48, and the blank 64 is now'firmly engaged and pressed into flat condition. Suction applied to the diaphragm 54 through the connection 62 is now cut off and pressure admitted through the connection 51 so that the diaphragm 54 is forced upwardly and the blank 64. is 'molded in cooperation with the mold 46, as suggested in Fig. 8. In this operation pressure upon the diaphragm 4B may be reduced and the diaphragm allowed to contract and so compensate for the expansion which would otherwise take place in the material of the blank in being conformed from its original flat condition to a three-dimensional shape. The

molded blank, therefore, suiers no reduction in cross-section due to the drawing action of the dies and remains smooth and entirely free from wrinkles or pleats.

It will be noted that by means of the connections above described, the two diaphragms may be subjected independently to different pressure conditions and thus expanded to different degrees and at different stages of the cycle if desired.

The diaphragms 48 and 54 may be formed of natural or any selected synthetic rubber, usually in flat circular form from 1A" to l/" in thickness, but in some instances it may be desirable to mold the diaphragms into an approximation of the shapes shown in Fig. 6.

Having thus disclosed our invention and described in detail illustrative examples oi' its application, we claim as new and desire to secure by Letters Patent:

1. The process of molding fibrous sheet stock, which includes the steps of engaging the stock between opposed prestretched elastic diaphragms, and while so engaged imparting three-dimensional contour to the stock by dies acting through the diaphragms and simultaneously permitting the diaphragms to contract in proportion to the stock drawn inwardly by the dies.

2. The process of molding fibrous sheet stock as defined in claim 1 further characterized in that one of the diaphragms is expanded into contact with a fiat supporting surface, that a flat blank is placed upon the said diaphragm and.

engaged from above by a. prestretched diaphragm.

3. The process of molding fibrous sheet stock as defined in claim 1 further characterized in that one of the elastic diaphragms is prestretched by blowing it up while the second diaphragm is prestretched by-sucking it against a supporting surface.

4. The process of molding fibrous sheet stock, which includes the steps of stretching a pair of opposed elastic diaphragms, engaging the stock between the stretched diaphragms, allowing the diaphragms to contract with the stock held between them, and simultaneously with such contraction imparting three-dimensional contour to the stock by dies acting through the diaphragms and drawing in the stock at substantially the same rate it is moved by contraction of the diaphragms.

5. The process of molding fibrous stock, which includes the steps of expanding a pair of opposed elastic diaphragms into approximately hemispherical shape, forcing the expanded dlaphragms into engagement with a flat blank of fibrous stock and thereby flattening the diaphragms against the stock over a substantial area thereof, then forcing forming dies against the stock through the interposed diaphragms, and simultaneously permitting the diaphragms stock is-drawn inwardly by the action of thel forming dies.

6. The process of molding fibrous sheet stock,

which includes the steps of first expanding -oppositely disposed circular elastic diaphragms,

-next engaging a fibrous blank between' the ex- -panded diaphragms, and then molding the blank by dies acting through the diaphragms and at the same time pemitting the expanded diaphragms to contract.

7.- The process of molding fibrous sheet stock, which includes the steps of blowing up oppositely disposed circular elastic diaphragms into balloon form, moving together and flattening the blown, up diaphragms with a blank interposed between them; and molding the flat blank by dies acting through the diaphragms.

8. The process of molding fibrous sheet stock, comprising the steps of blowing up elastic diaphragms by internal pressure to balloon form, flattening the diaphragms by pressure against each other with a blank interposed between them,i molding the blank by dies acting through the diaphragms and at the same time forming a vacuum between one diaphragm and its die, separating the diaphragms to release the molded blank while one diaphragm is held by vacuum, and finally releasing the said diaphragm.

9. Molding apparatus comprising relatively movable supports each carrying an elastic diaphragm and forming therewith a pressure chamber, uid pressure connections to each of said chambers whereby the diaphragms may be expanded, provision for relieving pressure upon the diaphragms and permitting them to contract while maintained in pressure engagement with an interposed blank, and a three-dimensional die movable to act upon the blankwhile so engaged.

10. The process of molding conformable sheet stock, which includes, the steps of engaging the stock between opposed pre-stretched elastic diaphragms, and while so engaged imparting threedimensional contour to the stock by a die acting through one of the diaphragms .and simultaneously permitting at least one of the diaphragms to contract during the molding step in proportion to the stock displaced bythe die.

WALTER B. CLIFFORD. RICHARD R. WALTON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,063,084 Thomson May 27, 1913 1,206,656 Benedictus Nov. 28, 1916 1,275,926 Hughes Aug. 13, 1918 1,318,044 Bechman Oct. 7, 1919 1,547,871 Gaunberg July 28, 1925 1,637,532 Oliver Aug. 2, 1927 1,643,147 Angier Sept. 20, 1927 1,806,861 Owen May 26, 1931 1,844,487 Tyrrell Feb. 9, 1932 2,298,037 Crandell Oct. 6, 1942 2,406,738 Brophy Sept. 3, 1946 FOREIGN PATENTS Number Country Date 180,489 Great Britain of 1922 191,057 Switzerland of 1937 283,685 Great Britain Jan. 18, 1928 

